U.S. patent application number 15/303343 was filed with the patent office on 2017-02-09 for seat structure and a process for forming a seat structure by an additive manufacturing process.
The applicant listed for this patent is Johnson Controls Technology Company. Invention is credited to Mark HARRIS, Jeff LAHO, Eric MICHALAK, Dan SAKKINEN, Brennon WHITE.
Application Number | 20170036578 15/303343 |
Document ID | / |
Family ID | 54392983 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170036578 |
Kind Code |
A1 |
WHITE; Brennon ; et
al. |
February 9, 2017 |
SEAT STRUCTURE AND A PROCESS FOR FORMING A SEAT STRUCTURE BY AN
ADDITIVE MANUFACTURING PROCESS
Abstract
A seat structure including at least one frame having one or more
thin walled complex geometry structures and a process for forming
the at least one frame via an additive manufacturing process.
Inventors: |
WHITE; Brennon; (Novi,
MI) ; HARRIS; Mark; (West Bloomfield, MI) ;
SAKKINEN; Dan; (Highland, MI) ; MICHALAK; Eric;
(Northville, MI) ; LAHO; Jeff; (Canton,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson Controls Technology Company |
Plymouth |
MI |
US |
|
|
Family ID: |
54392983 |
Appl. No.: |
15/303343 |
Filed: |
May 7, 2015 |
PCT Filed: |
May 7, 2015 |
PCT NO: |
PCT/US15/29621 |
371 Date: |
October 11, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61990924 |
May 9, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60N 2/68 20130101; B60N
2/643 20130101; B33Y 80/00 20141201; B60N 2/5621 20130101 |
International
Class: |
B60N 2/68 20060101
B60N002/68; B60N 2/56 20060101 B60N002/56; B60N 2/64 20060101
B60N002/64 |
Claims
1. A seat, comprising: a structural frame comprising one or more
thin walled complex geometry structures, said one or more thin
walled complex geometry structures comprising one or more of
multiple internal channels and ribs, said one or more of multiple
channels and ribs defining a structure for supporting elements
within said structural frame, said one or more of said multiple
channels and said ribs defining one or more of structural loading
paths and a channel for one or more of transporting fluids and
receiving one or more components.
2. A seat in accordance with claim 1, wherein said structural frame
comprises one or more of a seat back and a cushion frame comprising
additive manufacturing material, said one or more thin walled
complex geometry structures comprising non-castable and
non-machinable portions.
3. A seat in accordance with claim 1, wherein said structure for
supporting elements within said structural frame comprises a first
component and a second component, said first component defining an
interior space, said second component being located in said
interior space.
4. A seat in accordance with claim 3, wherein said first component
is connected to said second component via said ribs.
5. A seat in accordance with claim 3, wherein said first component
and said second component define said channel, said second
component comprising a second component channel.
6. A seat in accordance with claim 5, wherein said channel defines
a fluid flow path, wherein a wire harness is arranged in said
second component channel.
7. A structural frame, comprising: a plurality of layers, each of
said layers being integrally connected to each other to form a
single, one-piece frame structure, said single, one-piece frame
structure comprising load support areas and non-load support areas,
said load support areas comprising a greater amount of material
than said non-load support areas.
8. A process, comprising: providing a designed structural frame;
calculating load and stress points of said designed structural
frame; fabricating a structural frame layer by layer based on said
calculated load and stress points of said designed structural frame
such that more layers of material are used in areas of said load
and stress points than in areas of said structural frame that are
not subject to load and stress.
9. A process in accordance with claim 8, wherein said designed
structural frame is designed using topological optimization
software that iteratively runs load and stress calculations to
optimize a minimum amount of material to construct said structural
frame.
10. A structural frame in accordance with claim 7, wherein said
plurality of layers comprise movable sections.
11. A process in accordance with claim 8, wherein said structural
frame is a one piece structural frame, said one piece structural
frame comprising movable sections built into the one piece
structural frame.
12. A structural frame in accordance with claim 7, wherein said
plurality of layers comprise embedded elements, said embedded
elements defining impact load areas of said one-piece frame
structure.
13. A structural frame in accordance with claim 12, wherein said
embedded elements comprise one or more geometric shapes, said one
or more geometric shapes comprising one or more of gussets and
darts, said one or more of said gussets and darts comprising
fusible links, said fusible links being deformable such that said
links deform when one or more of a load and a moment is applied to
said links.
14. A structural frame in accordance with claim 7, wherein the
plurality of layers comprises non-homogeneous materials.
15. A structural frame in accordance with claim 14, wherein said
one-piece frame structure comprises a first frame portion and a
second frame portion.
16. A structural frame in accordance with claim 15, wherein said
first frame portion defines an interior first frame portion space,
said second frame portion being arranged in said interior first
frame portion space.
17. A structural frame in accordance with claim 15, wherein said
second frame portion defines a second frame portion channel.
18. A structural frame in accordance with claim 15, wherein said
one-piece frame structure comprises a plurality of support
structures, each of said plurality of support structures engaging
said first frame portion and said second frame portion, wherein
said first frame portion is connected to said second frame portion
via said plurality of support structures.
19. A structural frame in accordance with claim 15, wherein said
first frame portion and said second frame portion define a channel
for receiving a fluid, said first frame portion comprising an
opening, said opening and said channel defining a fluid flow path
for delivering a fluid.
20. A structural frame in accordance with claim 15, wherein said
second frame portion channel receives one or more of electrical
wires and a wire harness.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a United States National Phase
application of International Application PCT/U52015/029621 filed
May 7, 2015 and claims the benefit of priority under 35 U.S.C.
.sctn.119 and 120 of U.S. provisional application 61/990,924 filed
May 9, 2014, the entire contents of which are incorporated herein
by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a seat structure and a
process for forming a seat structure by an additive manufacturing
process.
BACKGROUND OF THE INVENTION
[0003] Conventional seat structures are made with dozens of
components that are welded, bonded or mechanically fastened
together. Each component of conventional seat structure assemblies
is designed to provide one or more functions. This provides
conventional seat structures that are heavier than required and
more complex to facilitate current production requirements.
SUMMARY OF THE INVENTION
[0004] An object of the invention is provide a seat structure that
is durable, high in strength and lightweight.
[0005] According to the present invention, a seat comprises a
structural frame. The structural frame comprises one or more thin
walled complex geometry structures. The one or more thin walled
complex geometry structures comprise one or more of multiple
internal channels and ribs. The one or more of multiple channels
and ribs define a structure for supporting elements within the
structural frame. The one or more of the multiple channels and the
ribs define one or more of structural loading paths and a channel
for one or more of transporting fluids and receiving one or more
components.
[0006] The structural frame may be a seat back, a cushion or a
combination of the seat back and the cushion. The seat back and the
cushion may form a shell. A portion of the structural frame may
extend from a seatback area of the seat into a seat cushion area of
the seat.
[0007] The structural frame may comprise one or more of a seat back
and a cushion frame that comprises additive manufacturing material.
The one or more thin walled complex geometry structures may
comprise non-castable and non-machinable portions.
[0008] The structure for supporting elements within the structural
frame may comprise a first component and a second component. The
first component may define an interior space. The second component
may be located in the interior space. The one or more thin walled
complex geometry structures may comprise non-castable and
non-machinable portions.
[0009] The first component may be connected to the second component
via the ribs.
[0010] The first component and the second component may define the
channel. The second component may comprise a second component
channel.
[0011] The channel may define a fluid flow path. A wire harness may
be arranged in the second component channel.
[0012] According to the present invention, a structural frame
comprises a plurality of layers. Each of the layers is integrally
connected to each other to form a single, one-piece frame
structure. The single, one-piece frame structure comprises load
support areas and non-load support areas. The load support areas
comprise a greater amount of material than the non-load support
areas.
[0013] According to the present invention, a process comprises
providing a designed structural frame. Load and stress points of
the designed structural frame are calculated. A structural frame is
fabricated layer by layer based on the calculated load and stress
points of the designed structural frame such that more layers of
material are used in areas of the load and stress points than in
areas of the structural frame that are not subject to load and
stress.
[0014] The designed structural frame may be designed using
topological optimization software that iteratively runs load and
stress calculations to optimize a minimum amount of material to
construct the structural frame.
[0015] According to the present invention, a structural frame
comprises a plurality of layers that are integrally connected to
form a single, one-piece frame structure. The plurality of layers
comprise movable sections.
[0016] According to the present invention, a process comprises
fabricating a one piece structural frame layer by layer with
movable sections built into the one piece structural frame.
[0017] According to the present invention, a structural frame
comprises a plurality of layers integrally connected to form a
one-piece frame structure. The plurality of layers comprise
embedded elements. The embedded elements define impact load areas
of the one-piece frame structure.
[0018] The embedded elements may comprise one or more geometric
shapes. The one or more geometric shapes may comprise one or more
of gussets and darts. The one or more of the gussets and darts may
comprise fusible links. The fusible links may be deformable such
that the links deform when one or more of a load and a moment is
applied to the links.
[0019] According to the present invention, a structural frame
comprises a one-piece frame structure comprising non-homogeneous
materials.
[0020] The one-piece frame structure may comprise a first frame
portion and a second frame portion.
[0021] The first frame portion may define an interior first frame
portion space. The second frame portion may be arranged in the
interior first frame portion space.
[0022] The second frame portion may define a second frame portion
channel.
[0023] The one-piece frame structure may comprise a plurality of
support structures. Each of the plurality of support structures may
engage the first frame portion and the second frame portion. The
first frame portion may be connected to the second frame portion
via the plurality of support structures.
[0024] The first frame portion and the second frame portion may
define a channel for receiving a fluid. The first frame portion may
comprise an opening. The opening and the channel may define a fluid
flow path for delivering a fluid.
[0025] The second frame portion channel may receive one or more of
electrical wires and a wire harness.
[0026] The various features of novelty which characterize the
invention are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and
specific objects attained by its uses, reference is made to the
accompanying drawings and descriptive matter in which preferred
embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of a one-piece frame;
[0028] FIG. 2 is a partial perspective view of the frame showing
the minimum material required to support force distribution through
the frame;
[0029] FIG. 3 is a partial perspective view of the frame showing
material required on the outside of the frame to support force
distribution through the frame;
[0030] FIG. 4 is a partial perspective view of the frame showing
material required on the inside of the frame to support force
distribution through the frame;
[0031] FIG. 5 is a partial sectional view of the frame;
[0032] FIG. 6 is another perspective view of the frame;
[0033] FIG. 7 is a perspective view of a plurality of components
that form the frame;
[0034] FIG. 8 is a top view of the plurality of components of FIG.
7;
[0035] FIG. 9 is a cross sectional view of one of the components of
FIG. 7;
[0036] FIG. 10 is a perspective view of a seat;
[0037] FIG. 11 is a cross sectional view of the seat of FIG.
10;
[0038] FIG. 12 is yet another perspective view of the frame;
[0039] FIG. 13 is a lower perspective view of the frame; and
[0040] FIG. 14 is a perspective view of another embodiment of a
frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Referring to the drawings in particular, FIG. 1 is a
perspective view of a seat having a frame 1. The frame 1 is formed
in one piece by an additive manufacturing process. The frame may be
used to form a seat back structure, a seat cushion or a combination
of the seat back structure and the seat cushion, which forms a
shell. FIG. 1 shows the frame 1 forming a part of a seat back
structure. The additive manufacturing process may be a
three-dimensional printing process. Plastics and/or metal alloys
may be used in the three-dimensional printing process to form the
frame 1. The frame 1 has a thin walled complex geometry structure
3. The thin walled complex geometry structure 3 is formed via the
additive manufacturing process. The thin walled complex geometry
structure 3 is not able to be formed by a casting process and the
thin walled complex geometry structure 3 is not able to be formed
by a machining process. The thin walled complex geometry structure
3 is formed of a very thin wall thickness. The wall thickness of
the thin walled complex geometry structure 3 is 3 mm. or less,
preferably 1 mm. or less. The thin walled complex geometry
structure 3 includes support ribs 5. It is not possible to form the
thin walled complex geometry structure 3 via a machining process
since the ribs 5 are formed inside the thin walled complex
structure 3.
[0042] The frame 1 is formed by providing a design of the seat back
structure 1. The design of the frame 1 may be formed via
computer-implemented design software, such as a computer-aided
design (CAD) software. The design of the frame 1 is analyzed using
a topological design software to determine where material is
required on the frame 1 to transfer load from an upper area 9 of
the frame 1 to recliners 7 at a lower area 11 of the frame 1. Based
on the analysis provided by the topological design software
material thickness is provided only where necessary when the frame
1 is formed by the additive manufacturing process. FIGS. 2, 3, 4
show examples of the minimum material required to support force
distribution through the frame 1 based on the analysis provided by
the topological design software. FIG. 3 is a partial perspective
view of the frame 1 showing material 15 required on the outer
surface 13 of the frame 1 to support force distribution through the
frame 1. FIG. 4 is a partial perspective view of the frame 1 with
material 17 required on the inside of the frame 1 to support force
distribution through the frame. The material 17 may be added to
ribs 5 in a lower area of the frame 1 and material 19 may be
provided to ribs 5 in an upper area 23 of the frame 1.
[0043] FIG. 5 is a partial sectional view of the frame 1. The frame
1 includes the outer surface 13 and an inner surface 25. The inner
surface structure 25 defines an interior space 27. A plurality of
ribs 5 are provided in the interior space 27. The ribs 5 are formed
in the interior space 27 via the additive manufacturing
process.
[0044] FIG. 6 is another perspective view of the frame 1. The frame
1 has a headrest mounting structure 29 for mounting a headrest to
the frame 1. The headrest mounting structure 29 is formed via the
additive manufacturing process.
[0045] FIG. 7 is a perspective view of a plurality of components
31. The plurality of components are used to form the frame 1. The
components 31 may be used to form the seat cushion or the
combination of the seat back structure and the seat cushion. The
seat back structure and the seat cushion may form a shell. Each of
the components 31 has an outer component 33 and an inner component
35.
[0046] FIG. 8 is a top view of the plurality of components 31. The
outer component 33 and the inner component 35 are connected by a
plurality of support structures 37. The support structures 37 may
include the plurality of ribs 5. The outer component 33 may be
formed of a 1 mm. thin shelled outer wall. The inner component 35
may be formed of a thin shelled inner wall. The outer component 33
and the inner component 35 are formed via the additive
manufacturing process.
[0047] FIG. 9 is a cross sectional view of one of the components
31, which is representative of the structure of each of the
components 31. The outer component 33 and the inner component 35
define a channel 43. The outer component includes an opening 39.
Fluid, such as air, passes through the channel 43 and exits via the
opening 39. The fluid may be heated or cooled. The inner component
35 has an inner component channel 41. Electrical wires, including
wire harnesses, may extend through the inner component channel 41
such that the electrical wires, including wire harnesses, are
connected to the seat back structure 1. The inner component 35
protects the wire harnesses from being damaged
[0048] FIG. 10 is a perspective view of a seat 45. The seat 45
includes a seat back structure 52 and a seat cushion 47. The seat
back structure 52 is connected to an occupant support structure 49.
The frame 1 shown in FIGS. 1-9 is used to form one or more of the
seat back structure 52 and the seat cushion 47. Fluid is delivered
in a direction of the occupant support structure 49 via a fluid
flow path 51. The fluid flow path 51 is defined by the seat back
structure 1.
[0049] FIG. 11 is cross sectional view of a portion of the seat 45
of FIG. 10. Fluid is delivered in the direction of the occupant
support structure 49 by the fluid flow path 51, which includes the
opening 39. Fluid passes along the fluid flow path 51 and exits the
seat back structure 52 via the opening 39 in the direction of the
occupant support structure 49. A charging grid element 55 and an
attracting grid 57 are arranged in the fluid flow path 51. The
occupant support structure 49 is connected to the seat back
structure 52 via one or more occupant support structure attachment
elements 53. The one or more occupant support structure attachment
elements 53 may be formed on the seat back structure 52. In another
embodiment, the one or more occupant support structure attachment
elements 53 may be formed on the occupant support structure 49. The
occupant support structure attachment elements 53 may be in the
form of internal trim attachment hooks. A trim cover 59 covers the
occupant support structure 49. A support element 61 supports the
occupant structure 49.
[0050] FIG. 12 is yet another perspective view of the frame 1. The
frame 1 includes structural elements 63, 65, 67, 69. The structural
elements 63, 65, 67, 69 may be in the form of gussets or darts. The
structural elements 63, 65, 67, 69 are provided in the lower area
11 of frame 1. The structural elements 63, 65, 67, 69 are printed
on as structural fusible links during the additive manufacturing
process. When the structural elements 63, 65, 67, 69 are subjected
to a shock load, such as when the frame 1 is in a vehicular
accident, the structural elements 63, 65, 67, 69 buckle. The
additive manufacturing process allows for variations in thickness
of the structural elements 63, 65, 67, 69, including a wall
thickness of the structural elements 63, 65, 67, 69, to create one
or more tunable buckle zones. It is understood that any number of
structural elements may be provided.
[0051] FIG. 13 is a lower perspective view of the frame 1 that
includes the structural elements 63, 65, 67, 69.
[0052] FIG. 14 is a perspective view of another embodiment of a
frame P. The frame 1' may form a seat back, a seat cushion or a
combination of the seat back and the seat cushion to form a shell.
Instead of being formed as a single, one-piece structure, the frame
1' is formed of at least a plurality of frame components 3', 5',
7'. It understood that the frame 1' may be formed of at least two
frame components, but any number of frame components may be used.
Each of the frame components 3', 5', 7' are formed via the additive
manufacturing process, such as the three-dimensional printing
process, and each of the frame components 3', 5', 7' are connected
to each other to form the frame P. This makes it less expensive to
form the frame 1' since it reduces print time of the additive
manufacturing process and maximizes material usage. In another
embodiment, attachment features, such as snap elements and
interlock elements are printed into the structure of the frame
components 3', 5', 7' via a 3-D printing process (additive
manufacturing process). The snap elements and the interlock
elements allow the frame components 3', 5', 7' to be connected to
each other to form the frame 1'. In another embodiment, the frame
components 3', 5', 7' can be bonded together in many ways, such as
welding or adhesive bonding.
[0053] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles.
* * * * *